Welding cable with improved conductor orientation adjacent the terminals



Nov. 10, 1964 E. I. GROVE 3,156,750

WELDING CABLE WITH IMPROVED CONDUCTOR ORIENTATION ADJACENT THE TERMIN ALS 2 Sheets-Sheet l Filed June 11, 1963 INVENTOR 477 I (2 /0 1 6 E. GROVE ING CABLE WIT IENTATION ADJAC Nov. 10, 1964 H IMPROVED CONDUCTOR ENT THE TERMINALS 2 Sheets-Sheet 2 WELD Filed June 11 1965 INVENTOR. 477 I 6701 6.

b razwvr/si terminal sections.

United States Patent WELDING CABLE WITH IIVWRQVED CUNEEKITGR ORIENTATIGN ADEAQENT "fl-1E TERMENAEJS 'Earl I. Grove, Walled Lake, Mich, assignor to Gar Wood Industries, End, Wayne, Mich, a corporation oi Michigan Filed June 1-1, 1963, 3oz. N0. 2$7,ll64 9 Claims. (Cl. Thi -=15) This invention relates to electric cables and more particularly to cables utilized in high current, low voltage applications.

Welding cables for conducting welding current to the electrodes of welding apparatus have been constructed with a first or-central layer of flexible stranded conductors for conducting current of one polarity and with two additional or outer layers, one such outer layer being dis- .posed on each side of the central layer; the two outer layers serve to conduct current opposite in polarity to that carried by the central layer. Cables of this character are disclosed in my Patent No. 3,079,460, issued Pebruary 26 1963. With such a construction, reactance and kick etiects are minimized and a long useful life is attainable due to the reduction in wear and destruction of the individual strands.

Since these cables carry current of high magnitude, a considerable amount of heat is generated due to PR losses; the amount of heat generated could be reduced by :increasing the cross-sectional area of the conductors. Since it is economically desirable to use conductors having a minimum total cross-sectional area, it is conventional practice to locate conductors, having a minimum total area, within .a flexible, hose-like case and to circulate Water through thecase whereby the heat due to PR losses is carried away and the temperature of the cable is maintained at an acceptable level.

At each end of such a cable, the conductors of opposite polarity must be segregated and connected to separate It is desirable to incorporate such terminal sections into a single structure which is small enough in cross-section to permit the hose to be pulled oil over the terminal structure for servicing of the cable and/or replacement of the hose. The terminal structure also provides passage means for conducting the coolant t and from the interior of the flexible case.

It is also desirable that the conductors impose minimum resistance to flow of the coolant, such as Water, through the hose. Difficulty is often encountered in resorting and segregating the individual conductors for connection to their respective terminal sections, not only because this must be accomplished with a minimum of bulk or cross-sectional area in order to permit the use of a hose of minimal size and allow replacement of the hose, but also to insure that the conductors are not bunched or squeezed in such a manner as to impede the circulation of water through the cable. The formation of obstructions to flow of water has in fact been a common cause of overheatingand cable burnout failures.

It is an object of this invention to provide an electric cable of the layer type, that is, wherein each layer has a plurality of conductors, incorporating an improved arrangement of the conductors particularly in the resorting areas adjacent the terminals.

Other objects, features and advantages of the present invention will become apparent from the subject and description and the appended claims, taken in conjunction with the accompanying drawings in which:

FIGURE 1 is a substantially diametric, longitudinal sectional view of one end of; the welding cable and terminal assembly embodying the preferred form of the invention; 1

FIGURE 2 is a partially exploded perspective view of "ice the welding cable assembly of FIGURE 1 with the hose broken away and with the terminal sections of opposite polarity, together with the adjacent portions of the conductors connected thereto, separated to better illustrate the manner in which the conductors are disposed in the transition or resorting zone;

FIGURE 3 is a cross-sectional view taken substantially along the line 3-3 in FIGURE 2;

FIGURE 4 is a cross-sectional view taken substantially along the line 44 in FIGURE 1; and

FIGURE 5 is a cross-sectional View taken substantially along the line 55 in FIGURE 1.

Looking now to the drawings, the terminal structure 10 of my preferred welding cable assembly is of a known type and is composed of a pair of similarly constructed, generally semicylindrical terminal sections 12 and 14 which are separated from each other by an electrical insulating strip 16. The terminal sections 12 and 14 have generally flat confronting inner surface portions 18 and 20, respectively, which are separated by and engageable with opposite sides of the insulating member 16. The outer surfaces of sections 12 and 14 terminate at their forward ends in generally flat, cutback portions '26 and 28, respectively. A bolt 22 seated in an insulating bushing 2 located in the fiat portion 26 and threada'bly engageable with the flat portion 28 holds the terminal sections 12 and 14 together. Aligned bores 30, 32 and 34 extend through flat portions 26 and '28 and insulating member 16, respectively, and provide means whereby the terminal structure 16 can be electrically connected to welding apparatus.

The terminal section 14 has a cavity 36 opening through the inner surface portion 20 and a groove 40 therein extending about the forward periphery of the cavity 36.

A sealing member 42 of circular cross-section is located in groove 40 to prevent the leakage of water or other coolant between the inner surface portion 20 and the insulating member 16. In this regard, the terminal section 12 is similar in construction to the section 14.

The terminal sections 12 and 14 terminate at their rearward ends in generally semicircularly shaped :apertures or pockets 43 and 46, respectively. Secured within the pocket 45 of terminal section 14 are a plurality of rope conductors A, B, C and D, while secured within the pocket 48 of terminal section 12 are a plurality of rope conductors E, F and G. The various conductors can be mechanically connected, see FIGURE 5, to their respective terminal elements in the manner described in the Wretord Patent 2,504,777, issued April 18, In securing these conductors to their terminal sections, the rearward portions, as 44 of inner surface portion 20 in section 14, are depressed and provide a passage for coolant in a manner to be seen. A flexible, resilient hose or casing St? is pulled over the conductors A-G and is clamped about the semicircular portion of terminal sections 12 and 14 by circumferentially extending clamp members 52 and 54-. Terminal sections 12 and 14 are provided with a plurality of peripheral grooves 56 and 53, respectively, which aid in gripping the hose 5% and which also aid in sealing between the hose St) in the terminal sections 12 and 14.

Water or some other coolant is injected into the cable via tapped bores, as 38 in section 14, and passes through the cavities, as 36, through depressed portions, as 44, through the hose 5t and out at the opposite terminal structure, which is similar to it), to thereby cool the cable assembly.

Looking now to FEGURE 3, the conductors AG are oriented with respect to each other, as shown, along the length of the cable assembly and in accordance with conventional practice are continuously twisted or rotated about the longitudinal central axis of the cable assembly.

ers located on each side of the first layer (see FIGURE 3). In order that the paths for both polarities have substantially the same electrical resistance, the total crosssectional area of the conductors A-D is selected to be substantially equal to the total cross-sectional area of the conductors E-G. The conductor orientation of FIGURE 3 is maintained over substantially the entire length of the cable assembly excepting in the resorting zones, as area Z of FIGURE 2, at the opposite ends of the cable assembly.

Looking now to FIGURE 2, and ignoring the overall twist of the cable conductors (shown as left-hand twist), theconductors A-D, in the resorting zone Z, are pulled out of the orientation of FIGURE 3 by being led laterally of the axis of the cable substantially in a common direction, as indicated by the arrows WW of FIGURE 3, and are connected to the terminal section 14, while conductors E-G are pulled out and led laterally in the opposite direction, as indicated by arrow X, and are connected to the terminal section 12. The plane of separation of the two terminal sections l2, M- is perpendicular to the general direction of separation indicated by arrows W and X, again, however, disregarding'the overall twist (which will be referred to hereinafter). As previously noted, it is important that conductors A-G be kept at minimum bulk throughout their length and during resorting, all the way to where they are connected to their respective terminal sections 12, 14, so that conductors A-G are not squeezed and coolant may flow freely through all parts of and among the strands of the cable assembly.

Looking now to FIGURE 3, the overall twist of the peripheral conductors A-E and G about the axial conductor F is as indicated by the arrow Y. The indicated twist preferably continues throughout the resorting zone Z although such overall twist cannot be illustrated in the resorting zone in FIGURE 2 due to the showing of the parts of opposite polarity separated and spread apart.

Since the pocket 46 of terminal section 14 approximately defines a semi-circular cross-section, it can be considered to consist of two quadrants, generally indicated by the numerals 43 and 45 (FIGURE 4). The end portions of conductors A and B are located in quadrant 43 in the pocket 46 with the end portion of conductor B located proximate the pressed-in inner surface portion 44 and with the end portion of conductor A located radially outwardly from the portion 44 and in juxtaposition with conductor B. The end portions of conductors C and D are similarly located in the other quadrant 45 in the pocket 46 with the end portion of conductor D located proximate the pressed-in inner surface portion 44 and with the end portion of conductor C located radially outwardly from the portion 44 and in juxtaposition with conductor D. 1

The end portions of conductors E and G are located proximate the inner surface portion 44 of terminal section 12 in adjacent quadrants of the pocket 48 with the end ductors AG at the beginning of the resorting zone Z.

Each of the conductors A-G is preferably provided with a perforate sheath 53 of synthetic rubber or other suitable material having both insulating and low frictional characteristics, in accordance with the teaching of Wreford, Patent No. 2,939,902. The conductors B, D, E and G which are located proximate the confronting surface portions of terminal sections 12 and lid have their sheaths extending up to their respective terminal sections to insure proper insulation of conductors of opposite polarity (FIGURES 2 and 4). On the other hand, the conductors A, C, and F located at the outer extremities of their respective terminal sections 12 and 14 have their respective sheaths terminated a selected distance from the terminal sections 12 and 14 to further reduce the bulk at that location (FIGURES 2 and 4); the latter sheaths, of course, sufficiently cover conductors A, C and F to prevent short circuiting therebetween.

With a cable assembly constructed in accordance with the above description, the flow and circulation of coolant through the cable is relatively unrestricted since the conductors are maintained relatively loosely and are not squeezed together; likewise, the bulk or the peripheral cross-sectional area defined by the cable proximate the terminal elements is maintained at a minimum, thereby allowing the use of a hose of minimum dimension.

While it Will be apparent that the preferred embodiment of the invention disclosed is Well calculated to fulfill the objects above stated, it will be appreciated that the in vention is susceptible to modification, variation and change without departing from the proper scope or fair meaning of the subjoined claims.

What is claimed is:

l. A flexible welding cable having a longitudinal axis and for use with a terminal assembly having two sections lying on opposite sides of a plane of separation, said cable comprising: an intermediate portion including a plurality of longitudinally extending layers of conductors having a preselected orientation, said plurality of layers comprising a first layer of conductors, a second layer of conductors disposed on one side of said first layer, and a third layer of conductors disposed on the other side of said first layer; said cable having an end portion wherein all of the conductors of the first layer lie on one side of said plane for connection to one terminal section and all of the conductors of the second and third layers lie on the other side of said Plane for connection to the other terminal section, and a resorting zone between said intermediate and end portions, the conductors of said first layer in said resorting zone extending angularly laterally with respect to said axis in a first radial direction out of said preselected orientation for connection to said one terminal section, the conductors of said second layer and said third layer in said resorting zone extending angularly laterally of said axis in a generally radial direction opposite to said first direction out of said preselected orientation for connection to said other terminal section.

2. The cable of claim 1 further comprising a perforated insulating member covering each of those conductors of said first, second, and third layers connected to one of said terminal sections.

3. The cable of claim 1 further comprising a perforated insulating member covering each conductor of said first, second and third layers with selected ones of said insulating members terminating a preselected distance from said terminal sections.

4. The cable of claim 1 further including means disposed proximate to said resorting zone for holding the conductors of said plurality of layers in said intermediate portion in said preselected orientation.

5. A flexible welding cable having a longitudinal axis and for use with a terminal assembly having two sections lying on opposite sides of a plane of separation, said cables comprising: an intermediate portion including a plurality of longitudinally extending layers of conductors having a preselected orientation and with said. layers being twisted in one direction with respect to said axis, said plurality of layers in said preselected orientation s earer) comprising a first layer of conductors, a second layer of conductors disposed on one side of said first layer, and a third layer of conductors disposed on the other side of said first layer, said cable having an end portion wherein all of the conductors of said first layer lie on one side of said plane in: connection to one terminal section and all of the conductors of the second and third layers lie on the other side of said plane for connection to the other terminal section, and a resorting zone between said intermediate and end portions, the conductors of said first layer in said resorting zone extending angularly laterally with respect to said axis in a first radial direction out of said preselected orientation and being simultaneously twisted in said one direction for connection to said one terminal section, the conductors of said second and third layers in said resorting zone extending angularly laterally with respect to said axis in a general radial direction opposite to said first direction out of said preselected orientation and being simultaneously twisted in said one direction for connection to said other terminal section.

6. A flexible welding cable having a longitudinal axis and for use with a terminal assembly having two sections lying on opposite sides of a plane of separation, said cable comprising: an intermediate portion including a plurality of longitudinally extending layers of conductors having a preselected orientation, said plurality of layers comprising a first layer of conductors, a second layer of conductors disposed on one side of said first layer, and a third layer of conductors disposed on the other side of said first layer; said cable having an-end portion wherein all of the conductors of the first layer lie on one side of said plane for connection to one terminal section and all of the conductors of the second and third layers lie on the other side of said plane for connection to the other terminal section, and a resorting zone between said intermediate and end portions, the conductors of said first layer in said resorting zone extending angularly laterally with respect to said axis in a first radial direction out of said preselected orientation and generally perpendicular to said plane for connection to said one terminal section, the conductor of said second layer and said third layer in said resorting zone extending angularly laterally of said axis in a generally radial direction opposite to said first direction out of said preselected orientation and generally perpendicular to said plane for connection to said other terminal section.

7. A flexible welding cable having a longitudinal axis and for use with a terminal assembly having two sections lying on opposite sides of a plane of separation, said cables comprising: an intermediate portion including a plurality of longitudinally extending layers of conductors having a preselected orientation and with said layers being twisted in one direction with respect to said axis, said plurality of layers in said preselected orientation comprising a first layer of conductors, a second layer of conductors disposed on one side of said first layer, and a third layer of conductors disposed on the other side of said first layer, said cable having an end portion wherein all of the conductors of said first layer lie on one side of said plane for connection to one terminal section and all of the conductors of the second and third layers lie on the other side of said plane for connection to the other terminal section, and a resorting zone between said intermediate and end portions, the conductors of said first layer in said resorting zone eX- tending angularly laterally with respect to said aXis in a first radial direction generally perpendicular to said plane and out of said preselected orientation and being simultaneously twisted in said one direction for connection to said one terminal section, the conductors of said second and third layers in said resorting zone extending angularly laterally with respect to said axis in a general radial direction opposite to said first direction out of said preselected orientation and generally perpendicular to the length of said layers and with said layers being twisted in one direction about the central axis; said plurality of lasers comprising a first layer of three conductors, a second layer of two conductors disposed on one side of said first layer, and a third layer of two conductors dis posed on the other side of said first layer; end portions or" each of said first, second and third layers of conductors defining a resorting zone, said end portions of the conductors of said first layer extending radially from between said second and third layers in a first direction out of said preselected orientation and being simultaneously twisted in said one direction and being connected to a first of said terminal sections with each of two of the conductors of said first layer disposed in a different quadrant of said pocket of and proximate to said inner surface portion of said first terminal section and with the third of said first layer conductors disposed radially outwardly from said inner surface portion of and in said pocket of said first terminal section, said end portions of said second layer conductors extending radially from said one side of said first layer in a direction opposite to said first direction out of said pre elected orientation and being simultaneously twisted in said one direction and being connected to the other of said terminal sections with the other conductor of said second layer disposed in one quadrant of said pocket of and proximate to said inner surface portion of said other terminal section and with the other conductors of said second layer disposed in said one quadrant of said pocket of and radially outwardly from said inner surface of said other terminal section, said end portions of the conductors of said third layer extending radially from said other side of said first layer in said opposite direction and bein simultaneously twisted in said one direction and being connected to said other terminal section with one of the conductors of said third layer disposed in the other quadrant of said po ket of and proximate to said inner surface portion of said other terminal section and with the other conductor of said third layer disposed in said other'quadrant of said pocket of and radially outwardly from said inner surface portion of said other terminal section, a perforated insulating member covering each conductor of said first, second and third layers with said insulating members on said third conductor of said first layer and on said other conductors of said second and third layers terminating a preselected distance from said terminal sections.

9. The cable of claim 8 further including an insulating member disposed between said radially inner surfaces of said terminal sections, a fiexible casing defining fluid passageway and enclosing said first, second and third layers of conductors, and passage means in said pair of terminal sections in fluidcommunication with said passageway in said flexible casing.

References Cited by the Examiner UNITED STATES PATENTS 2,906,807 9/59 Wreford et al. 17415 2,939,902 6/ 60 Wreford l74-15 3,065,290 11/62 Grove 174l5 FOREIGN PATENTS 861,204 2/41 France.

JOHN F. BURNS, Primary Examiner. JOHN P. WILDMAN, Examiner. 

1. A FLEXIBLE WELDING CABLE HAVING A LONGITUDINAL AXIS AND FOR USE WITH A TERMINAL ASSEMBLY HAVING TWO SECTIONS LYING ON OPPOSITE SIDES OF A PLANE OF SEPARATION, SAID CABLE COMPRISING: AN INTERMEDIATE PORTION INCLUDING A PLURALITY OF LONGITUDINALLY EXTENDING LAYERS OF CONDUCTORS HAVING A PRESELECTED ORIENTATION, SAID PLURALITY OF LAYERS COMPRISING A FIRST LAYER OF CONDUCTORS, A SECOND LAYER OF CONDUCTORS DISPOSED ON ONE SIDE OF SAID FIRST LAYER, AND A THIRD LAYER OF CONDUCTORS DISPOSED ON THE OTHER SIDE OF SAID FIRST LAYER; SAID CABLE HAVING AN END PORTION WHEREIN ALL OF THE CONDUCTORS OF THE FIRST LAYER LIE ON ONE SIDE OF SAID PLANE FOR CONNECTION TO ONE TERMINAL SECTION AND ALL OF THE CONDUCTORS OF THE SECOND AND THIRD LAYERS LIE ON THE OTHER SIDE OF SAID PLANE FOR CONNECTION TO THE OTHER TERMINAL SECTION, AND A RESORTING ZONE BETWEEN SAID INTERMEDIATE AND END PORTIONS, THE CONDUCTORS OF SAID FIRST LAYER INSAID RESORTING ZONE EXTENDING ANGULARLY LATERALLY WITH RESPECT TO SAID AXIS IN A FIRST RADIAL DIRECTION OUT OF SAID PRESELECTED ORIENTATION FOR CONNECTION TO SAID ONE TERMINAL SECTION, THE CONDUCTORS OF SAID SECOND LAYER AND SAID THIRD LAYER IN SAID RESORTING ZONE EXTENDING ANGULARLY LATERALLY OF SAID AXIS IN A GENERALLY RADIAL DIRECTION OPPOSITE TO SAID FIRST DIRECTION OUT OF SAID PRESELECTED ORIENTATION FOR CONNECTION TO SAID OTHER TERMINAL SECTION. 